Engine - 4.6l (2v) Mercury Grand Marquis IV рестайлинг

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

a Refer to the appropriate procedure.

Note. For information, refer to the exploded view under the Assembly procedure in this article.

The 4.6L (281 CID) is a V-8 engine with the following features

1. Single overhead camshafts
2. Two valves per cylinder
3. Sequential Multi-Port Fuel Injection (SFI)
4. Aluminum cylinder heads
5. Cast iron, 90-degree V-cylinder block
6. Individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain
7. Electronic ignition system with 8 ignition coils
8. Electronic returnless fuel system

Identification

Always refer to these labels when installation of new parts is necessary or when checking engine calibrations. The engine parts often differ within a CID family. Verification of the identification codes will make sure that the correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional equipment and revisions. The Ford Master Parts Catalog contains a complete listing of the codes and their application.

Code Information

The engine code information label, located on the side of the valve cover and the front side of the valve cover, contains the following

1. Engine build date
2. Engine plant code
3. Engine code

Exhaust Emission Control System

Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered in the Introduction - Gasoline Engines article.

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 8 solenoid-operated fuel injectors

1. are mounted in the intake manifold.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.
4. are connected in series with the fuel pressure sensor.

A constant fuel pressure is maintained across the fuel injectors by the fuel pressure sensor. The fuel pressure sensor

1. is positioned upstream from the fuel injectors on the fuel rail.

Valve Train

The valve train operates as follows

1. Ball-tip hydraulic lash adjusters provide automatic lash adjustment.
2. Roller followers ride on the camshaft lobe, transferring the up-and-down motion of the camshafts to the valves in the cylinder heads.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the upper intake manifold.

Lubrication System

The engine lubrication system operates as follows

1. Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
2. Oil is pumped through the oil filter on the left front side of the cylinder block.
3. Oil enters the main gallery where it is distributed to the crankshaft main journals and to both cylinder heads.
4. From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and piston ring assembly.
5. The left cylinder head is fed from a drilling into the supply passage feeding the main gallery at the front of the cylinder block. The right cylinder head is fed from a drilling into the rear of the main gallery. Main gallery pressure is reduced as it enters the cylinder head galleries through fixed serviceable orifices, located at the upper part of the feed passages. It is this reduced pressure in the cylinder head galleries which feeds the camshaft journals, the hydraulic lash adjusters and the primary and secondary timing chain tensioners.
6. The camshaft lobe and roller followers are lubricated by splash created through valve train operation.

Oil Pump

The lubrication system of the 4.6L (2V) engine is designed to provide optimum oil flow to critical components of the engine through its entire operating range. The heart of the system is a positive displacement internal gear oil pump using top seal rotors. Generically this design is known as a gerotor pump, which operates as follows

1. The oil pump is mounted on the front face of the cylinder block.
2. The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
3. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump.
4. Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure, both at hot idle and maximum speed.
5. The relief valve calibration protects the system from excessive pressure during high viscosity conditions.
6. The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature and high-speed conditions.

Scheme 8

Refer to ENGINE SYSTEM - GENERAL INFORMATION article for basic mechanical concerns or refer to the Introduction - Gasoline Engines article.

Scheme 9

Scheme 10

Scheme 11

REMOVAL

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Disconnect the fuel tube spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(/mercury/grand-marquis/iv-2005-2011/remont/body-electrical/#battery-mounting-and-cables) article.
4. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
5. Remove the air cleaner and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/mercury/grand-marquis/iv-2005-2011/remont/removal-installation/#intake-air-distribution-and-filtering) article.
6. Remove the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS & WASHERS»(/mercury/grand-marquis/iv-2005-2011/remont/wiperwasher-systems/#wiper-system-washer-system) article.
7. Disconnect the 8 fuel injector electrical connectors.
8. Remove the 8 ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 4.6L (2V)»(ref-294058) article.
9. Remove the 2 bolts and the intake manifold shield.
10. Disconnect the brake booster vacuum hose from the intake manifold.
11. Disconnect the quick connect coupling Evaporative Emission (EVAP) canister purge valve hoses from the Throttle Body (TB) spacer and from the EVAP canister purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
12. Disconnect the quick connect coupling PCV tube from the TB spacer. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
13. Disconnect the EGR system module vacuum and electrical connectors.
14. Disconnect the intake manifold-to-TB spacer vacuum hose.
15. Disconnect the generator electrical connector.
16. Detach the 2 generator wiring harness retainers from the generator bracket.
17. Remove the 4 generator bracket bolts and the bracket.
18. Remove the coolant thermostat. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
19. Disconnect the throttle control and the Throttle Position (TP) sensor electrical connectors.
20. Release the heater hose spring clamp and disconnect the heater hose.
21. Remove the EGR system module tube. For additional information, refer to «ENGINE EMISSION CONTROL»(/mercury/grand-marquis/iv-2005-2011/remont/auxiliary-emission-control-systems/#engine-emission-control) article.
22. If equipped, detach the wire harness retainer from the intake manifold crash bracket.
23. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
24. Remove the intake manifold crash bracket bolt.
25. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
26. Remove the wire harness retainer from the rear of the intake manifold.
27. Remove the 8 bolts and the intake manifold. Remove and discard the intake manifold gaskets.
28. Clean the sealing surfaces.

INSTALLATION

1. Install new intake manifold gaskets.
2. Install the intake manifold and hand-tighten the 8 bolts.
3. Install the 8 ignition coil-on-plugs. For additional information, refer to «ENGINE IGNITION - 4.6L (2V)»(ref-294058) article.
4. Position the intake manifold crash bracket and loosely install the bolt and stud bolt.
5. Tighten the bolts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
6. Tighten the intake manifold crash bracket bolt. Tighten to 25 Nm (18 lb-ft).
7. Install the EGR system module tube. For additional information, refer to «ENGINE EMISSION CONTROL»(/mercury/grand-marquis/iv-2005-2011/remont/auxiliary-emission-control-systems/#engine-emission-control) article.
8. Install the intake manifold shield and the 2 bolts. Tighten to 10 Nm (89 lb-in).
9. Connect the throttle control and the TP sensor electrical connectors.
10. Install the coolant thermostat. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
11. Install the generator bracket and the 4 bracket bolts. Tighten to 10 Nm (89 lb-in).
12. Connect the generator electrical connector.
13. Attach the 2 generator wiring harness retainers to the generator bracket.
14. Connect the EVAP canister purge valve hoses to the TB and the EVAP canister purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
15. Connect the intake manifold vacuum hose to the TB spacer.
16. Connect the EGR system module vacuum and electrical connectors.
17. Connect the PCV tube quick connect coupling to the TB spacer. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
18. Connect the brake booster vacuum hose to the intake manifold.
19. Install the heater hose and spring clamp.
20. Connect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
21. Connect the 8 fuel injector electrical connectors.
22. Install the wire harness retainer to the rear of the intake manifold.
23. If equipped, attach the wire harness retainer to the intake manifold crash bracket.
24. Install the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS & WASHERS»(/mercury/grand-marquis/iv-2005-2011/remont/wiperwasher-systems/#wiper-system-washer-system) article.
25. Connect the fuel spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
26. Install the air cleaner and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/mercury/grand-marquis/iv-2005-2011/remont/removal-installation/#intake-air-distribution-and-filtering) article.
27. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(/mercury/grand-marquis/iv-2005-2011/remont/body-electrical/#battery-mounting-and-cables) article.
28. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
29. If equipped with fire suppression system, repower the system.

Valve Cover - RH

Material

Scheme 12

Scheme 13

Scheme 14

Scheme 15

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Disconnect the fuel tube spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(/mercury/grand-marquis/iv-2005-2011/remont/body-electrical/#battery-mounting-and-cables) article.
4. Remove the LH engine mount. For additional information, refer to «Engine Mount - LH»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__engine-mount-lh) .
5. Remove the Evaporative Emission (EVAP) canister purge valve. For additional information, refer to «EVAPORATIVE EMISSIONS»(/mercury/grand-marquis/iv-2005-2011/remont/auxiliary-emission-control-systems/#evaporative-emissions-system) article.
6. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
7. Disconnect the A/C compressor electrical connector.
8. Disconnect the PCV valve electrical connector.
9. Disconnect the A/C pressure sensor electrical connector.
10. Disconnect the electronic engine control electrical connector.
11. Disconnect the A/C accumulator switch electrical connector.
12. Disconnect the PCV tube quick connect coupling from the PCV valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
13. Disconnect the 4 RH ignition coil electrical connectors.
14. Disconnect the 3 wire harness retainers from the valve cover and position wire harness aside.
15. Lower the engine.
16. Loosen the 8 studs, the 3 bolts and remove the valve cover and discard the gasket. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

1. Apply a bead of silicone gasket and sealant in 2 locations shown in illustration where the engine front cover meets the cylinder head.
2. Install a new valve cover gasket and the valve cover. Tighten the fasteners in the sequence shown in illustration to 10 Nm (89 lb-in).
3. Raise the engine.
4. Position wire harness and connect the 3 wire harness retainers to the valve cover.
5. Connect the 4 RH ignition coil electrical connectors.
6. Connect the PCV tube quick connect coupling to the PCV valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
7. Connect the A/C accumulator switch electrical connector.
8. Connect the 3 electronic engine control electrical connectors.
9. Connect the A/C pressure sensor electrical connector.
10. Connect the PCV valve electrical connector.
11. Connect the A/C compressor electrical connector.
12. Connect the CKP sensor electrical connector.
13. Install the EVAP canister purge valve. For additional information, refer to «EVAPORATIVE EMISSIONS»(/mercury/grand-marquis/iv-2005-2011/remont/auxiliary-emission-control-systems/#evaporative-emissions-system) article.
14. Install the LH engine mount. For additional information, refer to «Engine Mount - LH»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__engine-mount-lh) .
15. Connect the fuel tube spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
16. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(/mercury/grand-marquis/iv-2005-2011/remont/body-electrical/#battery-mounting-and-cables) article.
17. If equipped with fire suppression system, repower the system.

Valve Cover - LH

Material

Scheme 16

1. Remove the air cleaner and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/mercury/grand-marquis/iv-2005-2011/remont/removal-installation/#intake-air-distribution-and-filtering) article.
2. Disconnect the 4 wiring harness retainers from the valve cover and position the wire harness aside.
3. Disconnect the crankcase ventilation tube quick connect coupling from the valve cover. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
4. Loosen the 11 fasteners and remove the LH valve cover and gasket. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

1. Apply a bead of silicone gasket and sealant in 2 locations shown in illustration where the engine front cover meets the cylinder head.
2. Position the LH valve cover and new gasket on the cylinder head. Tighten the fasteners in the sequence shown in illustration to 10 Nm (89 lb-in).
3. Connect the crankcase ventilation tube quick connect coupling to the valve cover. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
4. Position the wire harness and connect the 4 wiring harness retainers to the valve cover.
5. Install the air cleaner and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/mercury/grand-marquis/iv-2005-2011/remont/removal-installation/#intake-air-distribution-and-filtering) article.

Scheme 17

1. For additional information, refer to the appropriate procedures.

Crankshaft Pulley

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Strap Wrench 303-D055 (D85L-6000-A) or equivalent

Scheme 18

Scheme 19

Material

1. Remove the engine cooling fan and fan shroud. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
2. Rotate the tensioner clockwise and remove the accessory drive belt.
3. Remove the crankshaft pulley bolt.
4. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.

1. Apply sealant to the Woodruff key slot on the crankshaft pulley.
2. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
3. Install the bolt and washer. Tighten the bolt in 4 steps. Step 1: Tighten to 120 Nm (89 lb-ft). Step 2: Loosen the bolt one full turn. Step 3: Tighten to 50 Nm (37 lb-ft). Step 4: Tighten an additional 90 degrees.
4. Rotate the tensioner clockwise and install the accessory drive belt.
5. Install the engine cooling fan and the fan shroud. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.

Crankshaft Front Seal

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Front Oil Seal 303-635 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)

Material

1. Remove the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__crankshaft-pulley) .
2. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front seal.

1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
2. Using the Crankshaft Front Oil Seal Installer, Crankshaft Vibration Damper Installer and Front Cover Oil Seal Installer, install the crankshaft front seal into the engine front cover.
3. Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__crankshaft-pulley) .

Engine Front Cover

Material

Scheme 20

Scheme 21

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove both valve covers. For additional information, refer to «Valve Cover - RH»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__valve-cover-rh) or «Valve Cover - LH»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__valve-cover-lh) .
3. Remove the coolant pump. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
4. Remove the crankshaft front seal. For additional information, refer to «Crankshaft Front Seal»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__crankshaft-front-seal) .
5. Remove the 3 bolts and position the power steering pump aside.
6. Drain the engine oil. Install the drain plug when finished. Tighten to 23 Nm (17 lb-ft).
7. Remove the 4 front oil pan-to-engine front cover bolts.
8. Remove the bolt and the shield.
9. Remove the bolt and the accessory drive idler pulley.
10. Remove the bolts and the stud bolts in the sequence shown in illustration.
11. Remove the engine front cover from the front cover-to-cylinder block dowel.
12. Clean the gasket surfaces with a plastic scraping tool and metal surface prep.

1. Apply silicone gasket and sealant along the cylinder head-to-block surface and the oil pan-to-cylinder block surface.
2. Position the new engine front cover gaskets.
3. Install the engine front cover on the front cover-to-cylinder block dowel and loosely install the bolts.
4. Tighten the front cover fasteners in the sequence shown in illustration to 25 Nm (18 lb-ft). Item Part Number Description 1 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 2 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 3 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 4 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 5 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 6 W706508 Stud, hex-head pilot, M8 x 1.25 x 50 - M6 x 1 x 10 7 N808586 Stud, washer hex-head pilot, M8 x 1.25 - M6 x 1.0 x 86.35 8 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 9 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 10 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 11 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1 12 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1 13 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1 14 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1 15 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1
5. Install the accessory drive idler pulley and the bolt. Tighten to 25 Nm (18 lb-ft).
6. Install the shield and the bolts. Tighten to 25 Nm (18 lb-ft).
7. Loosely install the 4 front oil pan bolts.
8. Tighten the 4 front oil pan bolts in 2 stages. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten an additional 60 degrees.
9. Position the power steering pump and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
10. Install a new crankshaft front seal. For additional information, refer to «Crankshaft Front Seal»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__crankshaft-front-seal) .
11. Install the coolant pump. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
12. Install the valve covers. For additional information, refer to «Valve Cover - RH»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__valve-cover-rh) or «Valve Cover - LH»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__valve-cover-lh) .
13. Fill the engine with clean engine oil.
14. If equipped with fire suppression system, repower the system.

Timing Drive Components

Special Tools Illustration Tool Name Tool Number Aligner, Camshaft Position 303-557 (T96T-6256-B) Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Compressor, Valve Spring 303-581 (T97T-6565-A) Holding Tool, Crankshaft 303-448 (T93P-6303-A)

Scheme 22

General Equipment

Material

Note. Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage can occur.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the engine front cover. For additional information, refer to «Engine Front Cover»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__engine-front-cover) .
3. Remove the crankshaft sensor ring from the crankshaft.
4. Disconnect the 8 ignition coil electrical connectors (4 shown in illustration).
5. Remove the bolts and the 8 ignition coils (4 shown in illustration).
6. Remove the 8 spark plugs.
7. Position the lobe of the camshaft up.
8. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
9. Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller followers.
10. Position the crankshaft with the keyway at the 12 o'clock position.
11. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
12. Remove the LH and RH timing chains and the crankshaft sprocket. Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Repeat for the LH timing chain and crankshaft sprocket.
13. Remove the timing chain guides. Remove the bolts. Remove the LH timing chain guide. Remove the bolts. Remove the RH timing chain guide.
14. Install the Camshaft Position Aligner.
15. Remove the bolt and the camshaft gear.

Engines with ratcheting timing chain tensioners

1. Compress each tensioner plunger, using an edge of a vise.
2. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
4. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation. Remove the tensioner from the vise.
5. Inspect the RH and LH timing chain tensioners. Install new tensioners as necessary.
6. Compress each tensioner plunger, using a vise.
7. Install a Hydraulic Chain Tensioner Retaining Clip on each tensioner to hold the plunger in during installation.
8. If the colored links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
9. Install the camshaft sprockets and new bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
10. Using the Crankshaft Holding Tool, position the crankshaft so the No. 1 cylinder is at Top Dead Center (TDC).
11. Install the crankshaft sprocket, making sure the flange faces forward.
12. Install the timing chain guide. Position the LH timing chain guide. Install and tighten the LH bolts to 10 Nm (89 lb-in). Position the RH timing chain guide. Install and tighten the RH bolts to 10 Nm (89 lb-in).
13. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 1 o'clock position.
14. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
15. Install the LH timing chain on the sprocket, aligning the colored (marked) link with the timing marks on the sprocket.
16. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner. Tighten to 25 Nm (18 lb-ft).
17. Remove the paper clip from the LH timing chain tensioner.
18. Remove the Hydraulic Chain Tensioner Retaining Clip from the LH timing chain tensioner.
19. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
20. Install the RH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.
21. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner. Tighten to 25 Nm (18 lb-ft).
22. Remove the paper clip from the RH timing chain tensioner.
23. Remove the Hydraulic Chain Tensioner Retaining Clip from the RH timing chain tensioner.
24. Make sure that the colored (marked) chain links are lined up with the dots on the crankshaft sprocket and the camshaft sprockets.
25. Rotate the camshaft until the lobe is in the up position.
26. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
27. Install the camshaft roller followers. Install the Valve Spring Compressor. Compress the valve spring. Install the camshaft roller followers in their original locations.
28. Install the 8 spark plugs. Tighten to 18 Nm (159 lb-in).
29. Install the 8 ignition coils and bolts (4 shown in illustration). Tighten to 6 Nm (53 lb-in).
30. Connect the 8 ignition coil electrical connectors (4 shown in illustration).
31. Install the crankshaft sensor ring on the crankshaft.
32. Install the engine front cover. For additional information, refer to «Engine Front Cover»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__engine-front-cover) .
33. If equipped with fire suppression system, repower the system.

Valve Train Components - Exploded View

Note. LH shown in illustration, RH similar.

Scheme 23

1. For additional information, refer to the appropriate procedures.

Valve Springs

Special Tools Illustration Tool Name Tool Number Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Compressor, Valve Spring 303-581 (T97T-6565-A)

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the camshaft roller followers. For additional information, refer to «Camshaft Roller Follower»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__camshaft-roller-follower) .
3. Position the piston at the top of the stroke.
4. Remove the spark plugs. For additional information, refer to «ENGINE IGNITION - 4.6L (2V)»(ref-294058) article.
5. Install compressed air in the cylinder to hold both valves in position.
6. Using the Valve Spring Compressor, compress the valve springs.
7. Remove the valve spring retainer keys, the valve spring retainer and the valve spring.

1. Position the valve spring and the valve spring retainer.
2. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
3. Using the Valve Spring Compressor, compress the valve spring. Install the valve spring retainer keys.
4. Remove the Valve Spring Compressor and Valve Spring Compressor Spacer.
5. Install the camshaft roller followers. For additional information, refer to «Camshaft Roller Follower»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__camshaft-roller-follower) .
6. Install the spark plugs. For additional information, refer to «ENGINE IGNITION - 4.6L (2V)»(ref-294058) article.
7. If equipped with fire suppression system, repower the system.

Valve Seals

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-581 (T97T-6565-A) Installer, Valve Stem Oil Seal 303-383 (T91P-6571-A)

Scheme 24

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the valve springs. For additional information, refer to «Valve Springs»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__valve-springs) .
3. Remove the valve stem seals.

1. Use the Valve Spring Compressor and Valve Stem Oil Seal Installer to install the valve stem seals.
2. Install the valve springs. For additional information, refer to «Valve Springs»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__valve-springs) .
3. If equipped with fire suppression system, repower the system.

REMOVAL AND INSTALLATION

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the camshaft roller followers. For additional information, refer to «Camshaft Roller Follower»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__camshaft-roller-follower) .
3. Remove the hydraulic lash adjusters.
4. To install, reverse the removal procedure. If equipped with fire suppression system, repower the system.

Camshaft Roller Follower

Special Tools Illustration Tool Name Tool Number Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Compressor, Valve Spring 303-581 (T97T-6565-A)

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the valve covers. For additional information, refer to «Valve Cover - RH»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__valve-cover-rh) or «Valve Cover - LH»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__valve-cover-lh) .
3. Position the piston of the cylinder being repaired at the bottom of the stroke.
4. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
5. Using the Valve Spring Compressor, compress the valve springs and remove the camshaft roller followers.

1. Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller followers.
2. Remove the Valve Spring Compressor from between the valve spring.
3. Install the valve covers. For additional information, refer to «Valve Cover - RH»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__valve-cover-rh) or «Valve Cover - LH»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__valve-cover-lh) .
4. If equipped with fire suppression system, repower the system.

Camshaft

Material

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the camshaft roller followers. For additional information, refer to «Camshaft Roller Follower»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__camshaft-roller-follower) .
3. Remove the timing chain. For additional information, refer to «Timing Drive Components»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__timing-drive-components) .
4. Remove the bolt and the camshaft sprocket and spacer.
5. Remove the 13 camshaft bearing cap bolts.
6. Remove the camshaft bearing cap.
7. Remove the camshaft from the cylinder head.

1. Lubricate the camshaft journals with clean engine oil.
2. Install the camshaft onto the cylinder head.
3. Lubricate the camshaft bearing cap with clean engine oil.
4. Install the camshaft bearing caps and loosely install the bolts.
5. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
6. Install the camshaft sprocket and bolt. Tighten the bolt in 2 stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
7. Install the timing chains. For additional information, refer to «Timing Drive Components»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__timing-drive-components) .
8. Install the roller followers. For additional information, refer to «Camshaft Roller Follower»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__camshaft-roller-follower) .
9. If equipped with fire suppression system, repower the system.

Scheme 25

Scheme 26

Scheme 27

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(/mercury/grand-marquis/iv-2005-2011/remont/body-electrical/#battery-mounting-and-cables) article.
3. Rotate the drive belt tensioner clockwise and remove the drive belt.
4. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
5. Disconnect the A/C compressor electrical connector.
6. Remove the bolt from the transmission cooler tube bracket.
7. Remove the nut and position aside the transmission cooler tube assembly.
8. Remove the 3 bolts and position aside the A/C compressor.
9. Remove the catalytic converter-to-exhaust manifold nuts and position aside the catalytic converter flange. Discard the nuts.
10. Remove the 8 nuts, the exhaust manifold and the gasket. Discard the nuts and gasket.
11. Remove and discard the 8 exhaust manifold studs.
12. Clean and inspect the exhaust manifold for flatness. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-system-general-information) article.

1. Install the 8 new exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
2. Install a new exhaust manifold gasket, the exhaust manifold and 8 new nuts. Tighten in sequence shown in illustration to 20 Nm (177 lb-in).
3. Position the catalytic converter flange and install the new catalytic converter-to-exhaust manifold nuts. Tighten to 48 Nm (35 lb-ft).
4. Position the A/C compressor and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).
5. Position the transmission cooler tube assembly and install the nut. To install, tighten to 9 Nm (80 lb-in).
6. Install the transmission cooler tube bracket bolt. To install, tighten to 15 Nm (133 lb-in).
7. Connect the A/C compressor electrical connector.
8. Connect the CKP sensor electrical connector.
9. Rotate the drive belt tensioner clockwise and install the drive belt.
10. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(/mercury/grand-marquis/iv-2005-2011/remont/body-electrical/#battery-mounting-and-cables) article.
11. If equipped with fire suppression system, repower the system.

Scheme 28

Scheme 29

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
3. Remove the intermediated shaft pinch bolt and detach the intermediate shaft from the steering gear and position aside.
4. Remove the 2 exhaust manifold heat shield bolts and the shield.
5. Remove the 2 catalytic converter-to-exhaust manifold nuts and position aside the catalytic converter flange. Discard the nuts.
6. Disconnect the EGR system module tube from the exhaust manifold.
7. Remove the LH Heated Oxygen Sensor (HO2S). For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(/mercury/grand-marquis/iv-2005-2011/remont/removal-installation/#electronic-engine-control-system) article.
8. Remove the 8 nuts, the exhaust manifold and the gasket. Discard the nuts and gasket.
9. Remove and discard the 8 exhaust manifold studs.
10. Clean and inspect the exhaust manifold for flatness. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-system-general-information) article.

1. Install the 8 new exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
2. Install a new exhaust manifold gasket, the exhaust manifold and 8 new nuts. Tighten in sequence shown in illustration to 20 Nm (177 lb-in).
3. Install the LH HO2S. For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(/mercury/grand-marquis/iv-2005-2011/remont/removal-installation/#electronic-engine-control-system) article.
4. Connect the EGR system module tube to the exhaust manifold. Tighten to 43 Nm (32 lb-ft).
5. Position the catalytic converter flange and install the new catalytic converter-to-exhaust manifold nuts. Tighten to 48 Nm (35 lb-ft).
6. Install the exhaust manifold heat shield and the 2 bolts. Tighten to 10 Nm (89 lb-in).
7. Position the intermediate shaft on the steering gear and install the pinch bolt. Tighten to 30 Nm (22 lb-ft).
8. If equipped with fire suppression system, repower the system.

Scheme 30

1. For additional information, refer to the appropriate procedures.

Oil Pan

Material

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the front crossmember. For additional information, refer to «FULL FRAME & BODY MOUNTING»(/mercury/grand-marquis/iv-2005-2011/remont/frames-subframes-crossmembers/#full-frame-and-body-mounting) article.
3. Remove the bolt and the nut. Position the transmission cooler tubes aside.
4. Drain the engine oil. Install the drain plug when finished. Tighten to 23 Nm (17 lb-ft).
5. Detach the 2 pin-type wire harness retainers.
6. Remove the oil pan bolts in the sequence shown in illustration.
7. Remove the oil pan and the gasket.

1. Clean and inspect the mating surfaces.
2. Apply silicone gasket and sealant at the rear seal retainer-to-cylinder block sealing surface.
3. Apply silicone gasket and sealant at the engine front cover-to-cylinder block mating surface.
4. Position the oil pan gasket and the oil pan.
5. Tighten the bolts in 2 stages, in the sequence shown in illustration. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Rotate an additional 60 degrees.
6. Attach the 2 pin-type wire harness retainers.
7. Position the transmission cooler tubes and install the bolt and the nut. Tighten the bolt to 15 Nm (133 lb-in). Tighten the nut to 9 Nm (80 lb-in).
8. Install the front crossmember. For additional information, refer to «FULL FRAME & BODY MOUNTING»(/mercury/grand-marquis/iv-2005-2011/remont/frames-subframes-crossmembers/#full-frame-and-body-mounting) article.
9. Fill the engine with clean engine oil.
10. Start the engine and check for leaks.
11. If equipped with fire suppression system, repower the system.

Material

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the oil pan. For additional information, refer to «Engine Lubrication Components - Exploded View, Oil Pan, Oil Pump, Oil Pump Screen and Pickup Tube»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v) and «Oil Pan»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__oil-pan) .
3. Remove the timing drive components. For additional information, refer to «Timing Drive Components»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__timing-drive-components) .
4. Remove the 3 bolts, the oil pump screen and pickup tube. Discard the O-ring seal.
5. Remove the 3 bolts and the oil pump.

1. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.
2. Position the oil pump and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
3. Position the oil pump screen and pickup tube and install the bolts. Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in). Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
4. Install the timing drive components. For additional information, refer to «Timing Drive Components»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__timing-drive-components) .
5. Install the oil pan. For additional information, refer to «Engine Lubrication Components - Exploded View, Oil Pan, Oil Pump, Oil Pump Screen and Pickup Tube»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v) and «Oil Pan»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__oil-pan) .
6. If equipped with fire suppression system, repower the system.

Oil Pump Screen and Pickup Tube

Material

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the oil pan. For additional information, refer to «Engine Lubrication Components - Exploded View, Oil Pan, Oil Pump, Oil Pump Screen and Pickup Tube»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v) and «Oil Pan»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__oil-pan) .
3. Remove the 3 bolts, the oil pump screen and pickup tube. Discard the O-ring seal.

1. Position the oil pump screen and pickup tube and install the bolts. Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in). Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
2. Install the oil pan. For additional information, refer to «Engine Lubrication Components - Exploded View, Oil Pan, Oil Pump, Oil Pump Screen and Pickup Tube»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v) and «Oil Pan»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__oil-pan) .
3. If equipped with fire suppression system, repower the system.

Oil Filter Adapter

Material

Scheme 31

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
3. Disconnect the lower radiator hose from the oil filter adapter.
4. Drain the engine oil. Install the drain plug when finished. Tighten to 23 Nm (17 lb-ft).
5. Remove and discard the oil filter.
6. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
7. If equipped, remove the oil cooler hose bolt and the oil cooler hoses from the oil filter adapter.
8. Remove the 4 bolts and the oil filter adapter and gasket. Discard the oil filter adapter gasket.

1. Clean the sealing surfaces.
2. Install a new gasket and the oil filter adapter and tighten the 4 bolts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
3. If equipped, install the oil cooler hoses to the oil filter adapter and install the bolt. Tighten to 10 Nm (89 lb-in).
4. Connect the EOP switch electrical connector.
5. Install the oil filter.
6. Connect the lower radiator hose to the oil filter adapter.
7. Fill the crankcase with clean engine oil.
8. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
9. If equipped with fire suppression system, repower the system.

Oil Cooler

Material

Scheme 32

Scheme 33

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
3. Remove and discard the oil filter. To install, lubricate the new oil filter O-ring seal with clean engine oil.
4. Remove the oil cooler hose bolt and remove the oil cooler hoses from the oil filter adapter. To install, tighten to 10 Nm (89 lb-in).
5. Disconnect the 2 coolant hoses from the oil cooler assembly.
6. Remove the wire nut from the engine front cover stud bolt and remove the oil cooler assembly. Inspect the oil cooler.
7. To install, reverse the removal procedure. If equipped with fire suppression system, repower the system.

Scheme 34

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and remove the EOP switch. To install, tighten to 14 Nm (124 lb-in), then tighten an additional 180 degrees.
3. To install, reverse the removal procedure. If equipped with fire suppression system, repower the system.

Oil Level Indicator and Tube

Material

Scheme 35

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the LH exhaust manifold. For additional information, refer to «Exhaust Manifold - LH»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v) .
3. Remove the oil level indictor.
4. Remove the bolt and the oil level indicator tube. To install, tighten to 10 Nm (89 lb-in).
5. Remove the O-ring seal and discard.
6. To install, reverse the removal procedure. If equipped with fire suppression system, repower the system. Lubricate the new O-ring seal and engine mating surface with clean engine oil.

Scheme 36

1. For additional information, refer to the appropriate procedures.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70E/4R75E»(/mercury/grand-marquis/iv-2005-2011/remont/automatic-trans/#automatic-transmission-4r70e4r75e) article.
3. Remove the 6 bolts and the flexplate.

1. Position the flexplate and loosely install the 6 bolts. Tighten the bolts in the sequence shown in illustration to 80 Nm (59 lb-ft).
2. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70E/4R75E»(/mercury/grand-marquis/iv-2005-2011/remont/automatic-trans/#automatic-transmission-4r70e4r75e) article.
3. If equipped with fire suppression system, repower the system.

Crankshaft Rear Seal

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH) Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH) Slide Hammer 100-001 (T50T-100-A)

Scheme 37

Scheme 38

Material

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the flexplate. For additional information, refer to «Flexplate»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v) .
3. Using the Crankshaft Rear Oil Slinger Remover and Slide Hammer, remove the crankshaft oil slinger.
4. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove the crankshaft rear seal.

1. Using the Crankshaft Rear Oil Seal Installers, install the crankshaft rear seal.
2. Using the Crankshaft Rear Oil Slinger Installer and Crankshaft Rear Oil Seal Installers, install the crankshaft oil slinger.
3. Install the flexplate. For additional information, refer to «Flexplate»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v) .
4. If equipped with fire suppression system, repower the system.

Crankshaft Rear Seal with Retainer Plate

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH) Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH) Lifting Bracket, Engine 303-D087 (D93P-6001-A1) Lifting Bracket, Engine 303-D088 (D93P-6001-A2) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH) Slide Hammer 100-001 (T50T-100-A) Support Bar, Engine 303-F072

Scheme 39

Material

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the flexplate. For additional information, refer to «Flexplate»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v) .
3. Remove the engine-to-transmission spacer plate.
4. Using the Crankshaft Rear Oil Slinger Remover and Slide Hammer, remove the crankshaft oil slinger.
5. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove the crankshaft rear seal.
6. Remove the 2 engine mount nuts.
7. Install the Engine Lifting Bracket to the RH cylinder head.
8. Install the Engine Lifting Bracket to the LH cylinder head.
9. Install the Engine Support Bar.
10. Using the Engine Support Bar, raise the engine.
11. Drain the engine oil. Install the drain plug when finished. Tighten to 23 Nm (17 lb-ft).
12. Detach the 2 pin-type wire harness retainers.
13. Remove the oil pan bolts in the sequence shown in illustration and partially lower the oil pan.
14. Remove the 3 bolts and position the oil pump screen and pickup tube into the oil pan and remove the oil pan. Discard the pickup tube O-ring seal. Discard the oil pan gasket.
15. Remove the 6 bolts and the crankcase rear seal retainer plate.

1. Clean and inspect the mating surface.
2. Apply a bead of gasket maker to the rear crankshaft seal retainer mating surface on the engine block.
3. Install the rear oil seal retainer plate and loosely install the 6 crankcase rear seal retainer plate bolts.
4. Tighten the rear seal retainer plate bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
5. Using the Crankshaft Rear Oil Seal Installers, install the crankshaft rear seal.
6. Using the Crankshaft Rear Oil Slinger Installer and Crankshaft Rear Oil Seal Installers, install the crankshaft oil slinger.
7. Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
8. Position the oil pump screen and pickup tube in the oil pan and position the oil pan and new gasket into the vehicle.
9. Position the oil pump screen and pickup tube and install the bolts. Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in). Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
10. Apply silicone gasket and sealant at the rear seal retainer-to-cylinder block sealing surface.
11. Apply silicone gasket and sealant at the engine front cover-to-cylinder block mating surface.
12. Install the oil pan bolts, tighten in the sequence shown in illustration, in 2 stages. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Rotate an additional 60 degrees.
13. Attach the 2 pin-type wire harness retainers.
14. Align the engine mount studs and lower the engine.
15. Install the 2 engine mount nuts. Tighten to 90 Nm (66 lb-ft).
16. Install the engine-to-transmission spacer plate.
17. Install the flexplate. For additional information, refer to «Flexplate»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v) .
18. Fill the engine with clean engine oil.
19. Start the engine and check for leaks.
20. If equipped with fire suppression system, repower the system.

Engine Mount - RH

Special Tools Illustration Tool Name Tool Number Lifting Bracket, Engine 303-050 (T70P-6000) Support Bar, Engine 303-F072

Scheme 40

Scheme 41

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the generator. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/charging-system/#charging-system-general-information) article.
3. Install the Engine Lifting Bracket.
4. Install the Engine Support Bar.
5. Remove the RH and LH lower engine mount nuts. To install, tighten to 90 Nm (66 lb-ft).
6. Using the Engine Support Bar, raise the engine.
7. Remove the 3 RH engine mount bolts. To install, tighten to 70 Nm (52 lb-ft).
8. Remove the RH engine mount.
9. To install, reverse the removal procedure. If equipped with fire suppression system, repower the system

Engine Mount - LH

Special Tools Illustration Tool Name Tool Number Lifting Bracket, Engine 303-050 (T70P-6000) Support Bar, Engine 303-F072

Material

Scheme 42

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the generator. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/charging-system/#charging-system-general-information) article.
3. Install the Engine Lifting Bracket.
4. Install the Engine Support Bar.
5. Remove the oil filter and discard. Lubricate the new oil filter O-ring seal with clean engine oil prior to installation.
6. Remove the LH and RH lower engine mount nuts. To install, tighten to 90 Nm (66 lb-ft).
7. Using the Engine Support Bar, raise the engine.
8. Remove the 3 bolts and the LH engine mount. To install, tighten to 70 Nm (52 lb-ft).
9. To install, reverse the removal procedure. If equipped with fire suppression system, repower the system.

Cylinder Head

Special Tools Illustration Tool Name Tool Number Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Compressor, Valve Spring 303-567 (T97P-6565-AH) Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)

Material

Cylinder heads

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the engine. For additional information, refer to «Engine»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v) .
3. Remove the bolts and the flexplate.
4. Remove the engine/transmission spacer plate.
5. Using the Engine Lifting Bracket Set, mount the engine on a suitable engine stand.
6. Remove the bolts and the RH engine mount.
7. Remove the drain plugs from the engine block. Allow the coolant to completely drain. Install the drain plugs when finished. To install, tighten to 20 Nm (177 lb-in).
8. Remove the bolt and the battery cables from the engine.
9. Disconnect the EGR tube from the exhaust manifold.
10. Disconnect the 8 ignition coil electrical connectors (4 shown in illustration).
11. Disconnect the 8 fuel injector electrical connectors (4 shown in illustration).
12. Remove the 2 bolts and the intake manifold shield.
13. Remove the crankcase ventilation tube.
14. Disconnect the generator electrical connector and detach the wire harness retainer.
15. Remove the generator mounting bracket. Remove the 4 bolts. Remove the bracket.
16. Disconnect the throttle control and the Throttle Position (TP) sensor electrical connectors.
17. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
18. Disconnect the Camshaft Position (CMP) sensor electrical connector.
19. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.
20. Disconnect the fuel charging wiring from the crash bracket and the wiring support bracket and remove the harness from the engine.
21. Disconnect the EGR tube nut from the EGR system module.
22. Remove the generator. Remove the 2 bolts. Remove the generator.
23. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
24. Remove the intake manifold crash bracket stud bolt.
25. Remove the 8 bolts and the 8 ignition coils (4 shown in illustration).
26. Remove the 2 bolts and the coolant outlet adapter.
27. Remove the thermostat.
28. Remove the 8 bolts and the intake manifold. Discard the intake manifold gaskets.
29. Clean the sealing surfaces.
30. Remove the coolant bypass tube. Remove the retaining nut. Remove the ground strap. Remove the coolant bypass tube.
31. Loosen the studs and bolts and remove the LH valve cover. Clean the mating surface and discard gasket.
32. Loosen the studs and bolts and remove the RH valve cover. Discard the gasket.
33. Remove the spark plugs.
34. Position the lobe of the camshaft upward.
35. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
36. Using the Valve Spring Compressor, compress the valve springs and remove the camshaft roller followers.
37. Remove the 16 hydraulic lash adjusters (4 shown in illustration).
38. Remove the bolt and the belt idler pulley.
39. Remove the coolant pump pulley.
40. Remove the crankshaft pulley bolt.
41. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
42. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front oil seal.
43. Remove the front 4 oil pan bolts.
44. Remove the 15 fasteners in the sequence shown in illustration.
45. Remove the engine front cover from the cylinder block. Discard the gaskets.
46. Remove the crankshaft sensor ring.
47. Position the crankshaft with the keyway at the 12 o'clock position.
48. Remove the timing chain tensioning system from both timing chains. Remove the bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
49. Remove the LH and RH timing chains and the crankshaft sprocket. Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Repeat for the LH timing chain and crankshaft sprocket.
50. Remove both timing chain guides. Remove the bolts. Remove the LH timing chain guide. Remove the bolts. Remove the RH timing chain guide.
51. Remove the RH exhaust manifold. Remove the nuts and discard. Remove the RH exhaust manifold. Remove and discard the RH exhaust manifold gasket.
52. Remove and discard the 8 RH exhaust manifold studs.
53. Remove the LH exhaust manifold. Remove the nuts and discard. Remove the LH exhaust manifold. Remove and discard the LH exhaust manifold gaskets.
54. Remove and discard the 8 LH exhaust manifold studs.
55. Remove the bolt and the oil level indicator tube.
56. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-system-general-information) article.
57. Install the Cylinder Head Remover/Installer on both ends of the cylinder head.
58. Remove the bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
59. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
60. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
61. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-system-general-information) article.

Special Tools Illustration Tool Name Tool Number Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) Includes Lifting Bracket, Engine 303-D087 and 303-D088 or equivalent Socket, Exhaust Gas Oxygen Sensor 303-476 (T94P-9472-A)

Material

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
3. Remove the hood.
4. Disconnect both battery cables. For additional information, refer to «BATTERY, MOUNTING & CABLES»(/mercury/grand-marquis/iv-2005-2011/remont/body-electrical/#battery-mounting-and-cables) article.
5. Remove the air cleaner and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/mercury/grand-marquis/iv-2005-2011/remont/removal-installation/#intake-air-distribution-and-filtering) article.
6. Remove the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS & WASHERS»(/mercury/grand-marquis/iv-2005-2011/remont/wiperwasher-systems/#wiper-system-washer-system) article.
7. Remove the 2 nuts and the support bracket.
8. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(/mercury/grand-marquis/iv-2005-2011/remont/accessory-drive-belts/#accessory-drive-system) article.
9. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
10. Disconnect the vacuum hose.
11. Disconnect the Evaporative Emission (EVAP) canister purge valve. Disconnect the 2 quick release EVAP hoses. Disconnect the electrical connector.
12. Disconnect the fuel tube spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
13. Detach the generator battery cable retainer from the RH valve cover stud bolt.
14. Remove the nut and disconnect the generator battery cable. Detach the generator battery cable pin-type retainer.
15. Disconnect the PCM electrical connectors.
16. Remove the bolt and ground wire.
17. Disconnect the A/C electrical connector.
18. Disconnect the A/C low charge protection switch electrical connector.
19. Disconnect the heater hoses.
20. Remove the bolt and the ground strap.
21. Disconnect the upper radiator hose from the hose connection. Secure the hose to the radiator assembly.
22. Disconnect the lower radiator hose from the oil filter adapter.
23. Remove the cooling fan. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
24. Drain the engine oil. Install the drain plug when finished. To install, tighten to 23 Nm (17 lb-ft).
25. Remove and discard the oil filter.
26. If equipped, disconnect the block heater electrical connector.
27. Disconnect the power steering electrical connector.
28. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
29. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
30. If equipped, remove and discard the oil cooler. For additional information, refer to «Oil Cooler»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__oil-cooler) .
31. Remove the nut and the transmission cooler tube support bracket.
32. Remove the transmission oil cooler tube bracket bolt.
33. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
34. Position the power steering tube bracket aside.
35. Disconnect the engine wiring harness retainers from the A/C compressor.
36. Disconnect the A/C compressor electrical connector.
37. Remove the 3 bolts and position the A/C compressor aside.
38. Remove the 3 bolts and position the power steering pump aside.
39. Remove the starter motor. For additional information, refer to «STARTING SYSTEM»(/mercury/grand-marquis/iv-2005-2011/remont/starter/#starting-system) article.
40. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connectors.
41. Disconnect the LH HO2S electrical connector.
42. Using the Exhaust Gas Oxygen Sensor Socket, remove the LH HO2S.
43. Support the exhaust and remove the 4 nuts. Discard the 4 nuts.
44. Remove the 2 engine mount nuts.
45. Install a suitable lifting device under the transmission and support.
46. Remove the rear transmission insulator nuts.
47. Raise the transmission and remove the rear transmission insulator bolts.
48. Remove the transmission rear insulator and lower the transmission down to rest on the rear crossmember.
49. Disconnect the HO2S sensor and the solenoid body sensor electrical connectors.
50. Disconnect the Output Shaft Speed (OSS) sensor, Transmission Range (TR) sensor and the Turbine Shaft Speed (TSS) sensor electrical connectors.
51. Release the wiring harness from the retainers on the transmission.
52. Remove the 3 bolts and the inspection cover.
53. Remove the torque converter nut access plug. Remove the 4 nuts.
54. Remove the 4 bolts and 1 stud (2 bolts shown in illustration).
55. Install the Engine Lifting Bracket to the RH cylinder head.
56. Install the Engine Lifting Bracket to the LH cylinder head.
57. Install the Engine Lifting Bracket Set.
58. Remove the 2 bellhousing bolts.
59. Remove the engine assembly from the vehicle.

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-567 (T97P-6565-AH) Cylinder Ridge Reamer 303-016 (T64L-6011-EA) Installer, Connecting Rod 303-442 (T93P-6136-A) Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) Includes Lifting Bracket, Engine 303-D087 and 303-D088 Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH) Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Remover/Installer, Cylinder Head 303-572 (T97T-6000-A) Slide Hammer 100-001 (T50T-100-A) Spacer, Valve Spring Compressor 303-382 (T91P-6565-AH)

Material

DISASSEMBLY

Note. Servicing the bottom end of the engine (crankshaft, bearings) requires that cylinder heads be removed. Failure to do so may result in engine damage.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan may cause engine failure.

Note. The crankshaft rear seal, the rear oil seal slinger and the crankshaft rear seal retainer plate must be removed before mounting the engine on the engine stand.

Note. For additional information, refer to the exploded views under engine Assembly in this article.

1. Remove the 6 bolts and the flexplate.
2. Remove the engine/transmission spacer plate.
3. Using the Crankshaft Rear Oil Slinger Remover and Slide Hammer, remove the crankshaft rear seal slinger.
4. Using the Crankshaft Rear Oil Seal Remover and Slide Hammer, remove the crankshaft rear seal.
5. Remove the 2 oil pan-to-crankcase rear seal retainer plate bolts and the 6 crankcase rear seal retainer plate bolts.
6. Using the Engine Lifting Bracket Set, mount the engine on a suitable engine stand.
7. Remove the bolts and the LH and RH engine mounts.
8. Remove the drain plugs from the engine block. Allow the coolant to completely drain. Install the drain plugs when finished. To install, tighten to 20 Nm (177 lb-in).
9. Remove the bolt and the battery cables from the engine.
10. Disconnect the EGR tube from the exhaust manifold.
11. Disconnect the 8 ignition coil electrical connectors (4 shown in illustration).
12. Disconnect the 8 fuel injector electrical connectors (4 shown in illustration).
13. Remove the 2 bolts and the intake manifold shield.
14. Disconnect and remove the crankcase ventilation tube.
15. Disconnect the generator electrical connector and detach the wiring harness retainer.
16. Remove the 4 generator mounting bracket bolts and the bracket.
17. Disconnect the throttle control and the Throttle Position (TP) sensor electrical connectors.
18. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
19. Disconnect the Camshaft Position (CMP) sensor electrical connector.
20. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.
21. Disconnect the Knock Sensor (KS) electrical connector and the wiring harness pin-type retainer.
22. Disconnect the vacuum hoses and the electrical connector.
23. Disconnect the fuel charging wiring from the intake manifold crash bracket and remove the harness from the engine assembly.
24. Disconnect the EGR tube nut from the EGR valve.
25. Remove the 2 generator bolts and the generator.
26. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
27. Remove the intake manifold crash bracket stud bolt.
28. Remove the 8 bolts and the 8 ignition coils (4 shown in illustration).
29. Remove the 2 bolts and the coolant outlet adapter.
30. Remove the thermostat.
31. Remove the 8 bolts and the intake manifold. Discard the intake manifold gaskets.
32. Clean the sealing surfaces.
33. Remove the coolant bypass tube. Remove the retaining nut. Remove the ground strap. Remove the coolant bypass tube.
34. Remove the nut and the KS.
35. Loosen the 6 studs and 5 bolts and remove the LH valve cover. Discard the gasket.
36. Loosen the 7 studs and 4 bolts and remove the RH valve cover. Discard the gasket.
37. Remove the 8 spark plugs.
38. Position the lobe of the camshaft upward.
39. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
40. Using the Valve Spring Compressor, compress the valve springs and remove the 16 camshaft roller followers.
41. Remove the 16 hydraulic lash adjusters (4 shown in illustration).
42. Remove the bolt and the accessory drive belt idler pulley.
43. Remove the 4 bolts and the coolant pump pulley.
44. Remove the 4 bolts and the coolant pump.
45. Remove the crankshaft pulley bolt.
46. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
47. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front seal.
48. Remove the 16 bolts and the oil pan. Discard the gasket.
49. Remove the 3 bolts, the oil pump screen and pickup tube.
50. Remove the oil pump screen and pickup tube spacer.
51. Remove the 15 fasteners in the sequence shown in illustration.
52. Remove the engine front cover from the cylinder block.
53. Remove the crankshaft sensor ring from the crankshaft.
54. Position the crankshaft with the keyway at the 12 o'clock position.
55. Remove the timing chain tensioning system from both timing chains. Remove the 4 bolts. Remove the timing chain tensioners. Remove the timing chain tensioner arms.
56. Remove the LH and RH timing chains and the crankshaft sprocket. Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Repeat for the LH timing chain and crankshaft sprocket.
57. Remove both timing chain guides. Remove the 4 bolts. Remove the LH timing chain guide. Remove the bolts. Remove the RH timing chain guide.
58. Remove the RH exhaust manifold. Remove the 8 nuts and discard. Remove the RH exhaust manifold. Remove the RH exhaust manifold gasket and discard.
59. Remove and discard the 8 RH exhaust manifold studs.
60. Remove the LH exhaust manifold. Remove the 8 nuts and discard. Remove the LH exhaust manifold. Remove the LH exhaust manifold gaskets and discard.
61. Remove and discard the 8 LH exhaust manifold studs.
62. Clean and inspect the exhaust manifolds. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-system-general-information) article.
63. Remove the bolt and the oil level indicator tube.
64. Install the Cylinder Head Remover/Installer on both ends of the cylinder head.
65. Remove the 10 bolts and the RH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
66. Remove the 10 bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
67. Clean the cylinder head-to-cylinder block mating surfaces of both cylinder heads and the cylinder block in the following sequence. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
68. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion paying particular attention to the oil pressure feed area. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-system-general-information) article.
69. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
70. Remove the 3 oil pump bolts and the oil pump.
71. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a Cylinder Ridge Reamer, following the manufacturer instructions.
72. Remove the 2 bolts and the connecting rod cap. Discard the bolts.
73. Using the Connecting Rod Installer, push the piston through the top of the cylinder block.
74. Remove the crankshaft bearing cap fasteners. Remove and discard the 10 cross-mounted main cap bolts. Loosen the 10 jack screws. Remove and discard the 10 main cap bolts.
75. Remove the 5 main bearing caps and the lower crankshaft main bearings.
76. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.

Special Tools Illustration Tool Name Tool Number Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Compressor, Valve Spring 303-567 (T97P-6565-AH) Installer, Valve Stem Oil Seal 303-383 (T91P-6571-A)

Material

Note. LH shown in illustration, RH similar.

Scheme 43

1. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
2. Using the Valve Spring Compressor, compress the valve springs.
3. Remove the valve spring retainer keys, the valve spring retainers, the valve springs and the valves.
4. Remove the valve stem seals.
5. Remove the bolts, the bearing caps and the camshaft.

ASSEMBLY

1. Use a plastic scraper and metal surface prep to clean the cylinder head.
2. Lubricate the camshaft journals with clean engine oil.
3. Install the camshaft and the camshaft bearing caps. Lubricate with clean engine oil and position the camshaft bearing caps. Install the bolts loosely.
4. Tighten the camshaft bearing caps bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
5. Install the valves in the cylinder head.
6. Using the Valve Stem Oil Seal Installer and Valve Spring Compressor, install the valve stem seals.
7. Install the valve springs and the valve spring retainers onto the valves.
8. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
9. Using the Valve Spring Compressor, compress the valve springs and install the valve spring retainer keys.
10. Remove the Valve Spring Compressor Spacer.

Piston

Material

Scheme 44

1. Remove the upper piston compression ring.
2. Remove the lower piston compression ring.
3. Remove the upper piston oil control segment ring.
4. Remove the piston oil control spacer.
5. Remove the lower piston oil control segment ring.
6. Remove the 2 piston pin retainers.
7. Remove the piston pin and remove the connecting rod from the piston.

1. Position the connecting rod in the piston.
2. Install the piston pin and the 2 piston pin retainers.
3. Install the lower piston oil control segment ring.
4. Install the piston oil control spacer.
5. Install the upper piston oil control segment ring.
6. Install the lower piston compression ring.
7. Install the upper piston compression ring.

Special Tools Illustration Tool Name Tool Number Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Compressor, Valve Spring 303-567 (T97P-6565-AH) Holding Tool, Crankshaft 303-448 (T93P-6303-A) Installer, Connecting Rod 303-442 (T93P-6136-A) Installer, Crankshaft Front Oil Seal 303-635 Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH) Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) Includes Lifting Bracket, Engine 303-D087 and 303-D088 Remover/Installer, Cylinder Head 303-572 (T97T-6000-A) Strap Wrench 303-D055 (D85L-6000-A) or equivalent

General Equipment

Material

Scheme 45

Scheme 46

Scheme 47

Scheme 48

All engines

1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the back of the crankshaft.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings Chart determine the required bearing grade for each main bearing. Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code. Read down the column below the engine main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 1 crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for this main bearing is "2." Repeat this process for the remaining 4 main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearing Chart to determine the required grade for each main bearing.
5. Lubricate with clean engine oil and install the crankshaft upper main bearings into the cylinder block.
6. Install the crankshaft onto the upper crankshaft thrust bearing and main bearings.
7. Install the rear main bearing cap.
8. Install the crankshaft lower main bearings, thrust bearing and thrust washer into the main bearing caps. Locate the main bearing cap on the cylinder block and tap into place using a plastic or dead-blow hammer.
9. Back out the 10 jackscrews against the cylinder block in 2 stages, in the sequence shown in illustration. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in).
10. Install the 10 main bearing cap bolts and tighten in 2 stages, in the sequence shown in illustration. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 21 Nm (15 lb-ft).
11. Tighten the 10 main bearing cap bolts in 2 stages, in the sequence shown in illustration. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
12. Check piston-to-cylinder block and ring clearances. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-system-general-information) article.
13. Use the Piston Ring Compressor and Connecting Rod Installer to install the piston and connecting rod assemblies. Lubricate the piston and ring with clean engine oil. Lubricate the rod bearings with clean engine oil. Rotate the crankshaft as necessary.
14. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.
15. Position the lower bearing and connecting rod bearing cap, and install the 2 new bolts loosely.
16. Tighten the 16 connecting rod bearing cap bolts in 3 stages, in the sequence shown in illustration. Stage 1: Tighten to 23 Nm (17 lb-ft). Stage 2: Tighten to 43 Nm (32 lb-ft). Stage 3: Rotate an additional 90-120 degrees.
17. Position the oil pump and install the 3 bolts loosely. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
18. Install the head gaskets over the dowel pins.
19. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
20. Tighten the 10 cylinder head bolts in 6 stages, in the sequence shown in illustration. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn). Stage 3: Loosen a minimum of one full turn (360 degrees). Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten an additional 90 degrees (1/4 turn). Stage 6: Tighten an additional 90 degrees (1/4 turn).
21. Remove the Cylinder Head Remover/Installer from both ends of the cylinder head.
22. Install the new 8 LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
23. Install a new LH exhaust manifold gasket the LH exhaust manifold and 8 new nuts. Tighten to 20 Nm (177 lb-in) in the sequence shown in illustration.
24. Install the new 8 RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
25. Install a new RH exhaust manifold gasket the RH exhaust manifold and 8 new nuts. Tighten to 20 Nm (177 lb-in) in the sequence shown in illustration.
26. Compress each tensioner plunger, using an edge or a vise.
27. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
28. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
29. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation. Remove the tensioner from the vise.
30. Inspect the RH and LH timing chain tensioners. Install new tensioners as necessary.
31. Compress each tensioner plunger, using a vise.
32. Install a Hydraulic Chain Tensioner Retaining Clip on the tensioner to hold the plunger in during installation.
33. If the colored links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
34. Using the Crankshaft Holding Tool, position the crankshaft. Remove the Crankshaft Holding Tool after crankshaft positioning.
35. Install the crankshaft sprocket, making sure the flange faces forward.
36. Install the timing chain guides. Position the LH timing chain guide. Install and tighten the 2 LH bolts to 10 Nm (89 lb-in). Position the RH timing chain guide. Install and tighten the 2 RH bolts to 10 Nm (89 lb-in).
37. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 1 o'clock position.
38. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
39. Install the LH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.
40. Position the LH timing chain tensioner on the dowel pin and install the LH timing chain tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft).
41. Remove the paper clip from the LH timing chain tensioner.
42. Remove the Hydraulic Chain Tensioner Retaining Clip from the LH timing chain tensioner.
43. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
44. Install the RH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.
45. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and 2 bolts. Tighten to 25 Nm (18 lb-ft).
46. Remove the paper clip from the RH timing chain tensioner.
47. Remove the Hydraulic Chain Tensioner Retaining Clip from the RH timing chain tensioner.
48. Make sure that the colored (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
49. Rotate and camshaft until the lobe is in the upward position.
50. Install the Valve Spring Compressor Spacer between the valve spring coil to prevent valve stem seal damage.
51. Install the 16 hydraulic lash adjusters in their original locations (4 shown in illustration).
52. Install the 16 camshaft roller followers. Install the Valve Spring Compressor. Compress the valve spring. Install the 16 camshaft roller followers in their original locations.
53. Remove the Valve Spring Compressor Spacer.
54. Install all 8 spark plugs. Tighten to 18 Nm (159 lb-in).
55. Install the crankshaft sensor ring.
56. Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.
57. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight.
58. Tighten the 15 front cover fasteners in the sequence shown in illustration to 25 Nm (18 lb-ft). Item Part Number Description 1 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 2 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 3 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 4 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 5 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 6 W706508 Stud, hex-head pilot, M8 x 1.25 x 50 - M6 x 1 x 10 7 N808586 Stud, washer hex-head pilot, M8 x 1.25 - M6 x 1.0 x 86.35 8 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 9 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 10 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 11 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1 12 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1 13 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1 14 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1 15 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1
59. Install the RH and LH engine mounts and the 6 bolts. Tighten to 70 Nm (52 lb-ft).
60. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
61. Using the Crankshaft Front Oil Seal Installer, Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the front oil seal.
62. Apply sealant to the Woodruff key slot on the crankshaft pulley.
63. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
64. Install the bolt and washer and tighten the crankshaft pulley bolt in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Rotate an additional 90 degrees (1/4 turn).
65. Install the oil pump screen and pickup tube spacer. Tighten to 25 Nm (18 lb-ft).
66. Position the oil pump screen and pickup tube, and install the 3 bolts. Tighten to 25 Nm (18 lb-ft). Tighten to 10 Nm (89 lb-in).
67. Install the new oil filter adapter gasket, oil filter adapter and the 4 bolts. Tighten to 25 Nm (18 lb-ft) in the sequence shown in illustration.
68. Install the coolant pump. Lubricate the new O-ring seal using clean engine coolant. Position the coolant pump into the engine block. Install the 4 bolts and tighten to 25 Nm (18 lb-ft).
69. Position the coolant pump pulley on the coolant pump and install the 4 bolts. Tighten to 25 Nm (18 lb-ft).
70. Position the accessory drive belt idler pulley and install the bolt. Tighten to 25 Nm (18 lb-ft).
71. Apply sealant in 2 places where the engine front cover meets the cylinder head.
72. Install the new LH gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
73. Apply sealant in 2 places where the engine front cover meets the cylinder head.
74. Install the new RH gasket into the valve cover and position on the cylinder head. Tighten the 11 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
75. Install the Knock Sensor (KS) and the nut. Tighten to 20 Nm (177 lb-in).
76. Inspect the O-rings seals. Install new seals, if necessary.
77. Install the coolant bypass tube.
78. Install the ground strap on the rear of the RH cylinder head. Install the stud bolt and tighten to 25 Nm (18 lb-ft). Install the ground strap. Install the retaining nut and tighten to 10 Nm (89 lb-in).
79. Install the new intake manifold gaskets, intake manifold and hand-tighten the 8 bolts at the locations shown in illustration.
80. Install the 8 ignition coils and tighten the 8 bolts (4 shown in illustration). Tighten to 6 Nm (53 lb-in).
81. Install the intake manifold crash bracket bolt and loosely install the bolt and the stud bolt.
82. Install the thermostat.
83. Install the coolant outlet adapter and loosely install the 2 bolts.
84. Tighten the 9 bolts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
85. Tighten the stud bolt. Tighten to 25 Nm (18 lb-ft).
86. Tighten the 2 coolant outlet adapter bolts. Tighten to 25 Nm (18 lb-ft).
87. Connect the throttle control and throttle positioning sensor electrical connector.
88. Connect the EGR tube to the EGR valve. Tighten to 43 Nm (32 lb-ft).
89. Connect the EGR tube to the exhaust manifold. Tighten to 43 Nm (32 lb-ft).
90. Position the fuel charging wiring at 2 locations at the back of the intake manifold.
91. Install the generator and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
92. Install the generator mounting bracket and the 4 bolts. Tighten to 10 Nm (89 lb-in).
93. Attach the wire harness retainer and connect the generator electrical connector.
94. Position the vacuum harness and connect the vacuum hoses for the Evaporative Emission (EVAP) canister purge valve, the main chassis hose and the EGR valve.
95. Connect the crankcase ventilation tube.
96. Install the intake manifold shield and 2 bolts. Tighten to 10 Nm (89 lb-in).
97. Connect the 8 fuel injector electrical connectors (4 shown in illustration).
98. Connect the 8 ignition coil electrical connectors (4 shown in illustration).
99. Connect the Camshaft Position (CMP) sensor electrical connector.
100. Connect the radio interference capacitor electrical connector.
101. Connect the KS electrical connector and install the harness retainer to the intake manifold.
102. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
103. Install the battery cables and the bolt.
104. Install the Engine Lifting Bracket to the RH cylinder head.
105. Install the Engine Lifting Bracket to the LH cylinder head.
106. Using the Engine Lifting Bracket Set, remove the engine from the engine stand.
107. Apply a bead of gasket maker to the crankshaft rear seal retainer plate mating surface on the engine block.
108. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
109. Tighten the 6 crankshaft rear seal retainer plate bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
110. Apply the sealant at the rear oil seal retainer to cylinder block sealing surface.
111. Apply sealant at the front cover-to-cylinder block sealing surface.
112. Position the new oil pan gasket, the oil pan and the loosely install the 16 bolts.
113. Tighten the 16 bolts in 2 stages, in the sequence shown in illustration. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Rotate an additional 60 degrees.
114. Using the Crankshaft Rear Oil Seal Installers, install the crankshaft rear oil seal.
115. Using the Crankshaft Rear Oil Seal Installer and Crankshaft Rear Oil Slinger Installer, install the crankshaft oil slinger.
116. Install the engine/transmission spacer plate.
117. Position the flexplate and install the 6 bolts in the sequence shown in illustration. Tighten to 80 Nm (59 lb-ft).

Special Tools Illustration Tool Name Tool Number Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Compressor, Valve Spring 303-567 (T97P-6565-AH) Holding Tool, Crankshaft 303-448 (T93P-6303-A) Installer, Crankshaft Front Oil Seal 303-635 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) Includes Lifting Bracket, Engine 303-D087 and 303-D088 or equivalent Remover/Installer, Cylinder Head 303-572 (T97T-6000-A) Strap Wrench 303-D055 (D85L-6000-A) or equivalent

General Equipment

Material

Both cylinder heads

1. Install the new head gasket over the dowel pins.
2. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
3. Tighten the cylinder head bolts in 6 stages, in the sequence shown in illustration. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn). Stage 3: Loosen a minimum of one full turn (360 degrees). Stage 4: Tighten to 40 Nm (30 lb-ft). Stage 5: Tighten an additional 90 degrees (1/4 turn). Stage 6: Tighten an additional 90 degrees (1/4 turn).
4. Remove the Cylinder Head Remover/Installer from both ends of the cylinder head.
5. Install a new O-ring seal on the oil level indicator tube and install the oil level indicator tube and bolt. Tighten to 10 Nm (89 lb-in).
6. Install the 8 new LH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
7. Install a new LH exhaust manifold gasket the LH exhaust manifold and 8 new nuts. Tighten to 20 Nm (177 lb-in) in the sequence shown in illustration.
8. Install the 8 new RH exhaust manifold studs. Tighten to 12 Nm (106 lb-in).
9. Install a new RH exhaust manifold gasket the RH exhaust manifold and 8 new nuts. Tighten to 20 Nm (177 lb-in) in the sequence shown in illustration.
10. Compress each tensioner plunger, using an edge of a vise.
11. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
12. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
13. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation. Remove the tensioner from the vise.
14. Inspect the RH and LH timing chain tensioners. Install new tensioners as necessary.
15. Compress each tensioner plunger, using an edge of a vise.
16. Install a Hydraulic Chain Tensioner Retaining Clip on the tensioner to hold the plunger in during installation.
17. If the colored links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
18. Using the Crankshaft Holding Tool, position the crankshaft. Remove the Crankshaft Holding Tool after crankshaft positioning.
19. Install the crankshaft sprocket, making sure the flange faces forward.
20. Install the timing chain guides. Position the LH timing chain guide. Install and tighten the LH bolts to 10 Nm (89 lb-in). Position the RH timing chain guide. Install and tighten the RH bolts to 10 Nm (89 lb-in).
21. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 1 o'clock position.
22. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
23. Install the LH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.
24. Position the LH timing chain tensioner on the dowel pin and install the LH timing chain tensioner. Tighten to 25 Nm (18 lb-ft).
25. Remove the Hydraulic Chain Tensioner Retaining Clip from the LH timing chain tensioner.
26. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
27. Install the RH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.
28. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner. Tighten to 25 Nm (18 lb-ft).
29. Remove the Hydraulic Chain Tensioner Retaining Clip from the RH timing chain tensioner.
30. Make sure that the colored (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
31. Rotate the camshaft until the lobe is in the upward position.
32. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
33. Install the 16 hydraulic lash adjusters in their original locations (4 shown in illustration).
34. Install the camshaft roller follower. Install the Valve Spring Compressor. Compress the valve spring. Install the camshaft roller followers in their original locations.
35. Remove the Valve Spring Compressor Spacer.
36. Install all 8 spark plugs. Tighten to 18 Nm (159 lb-in).
37. Install the crankshaft sensor ring.
38. Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.
39. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
40. Tighten the front cover fasteners in the sequence shown in illustration to 25 Nm (18 lb-ft). Item Part Number Description 1 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 2 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 3 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 4 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 5 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 6 W706508 Stud, hex-head pilot, M8 x 1.25 x 50 - M6 x 1 x 10 7 N808586 Stud, washer hex-head pilot, M8 x 1.25 - M6 x 1.0 x 86.35 8 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 9 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 10 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53 11 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1 12 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1 13 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1 14 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1 15 N806300 Stud, hex-shoulder pilot, M8 x 1.25 x 1.25 x 91.1
41. Loosely install the 4 bolts, then tighten in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 20 Nm (177 lb-in). Stage 2: Tighten an additional 60 degrees.
42. Install the RH and LH engine mounts and the bolts. Tighten to 70 Nm (52 lb-ft).
43. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
44. Using the Crankshaft Front Oil Seal Installer, Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the front oil seal.
45. Apply sealant to the Woodruff key slot on the crankshaft pulley.
46. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
47. Tighten the crankshaft pulley bolt in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Rotate an additional 90 degrees (1/4 turn).
48. Position the coolant pump pulley on the coolant pump and install the bolts. Tighten to 25 Nm (18 lb-ft).
49. Install the accessory drive belt idler pulley and bolt. Tighten to 25 Nm (18 lb-ft).
50. Apply sealant in 2 places where the engine front cover meets the cylinder head.
51. Install the new valve cover gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
52. Apply sealant in 2 places where the engine front cover meets the cylinder head.
53. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
54. Inspect the O-ring seals. Install new seals if necessary.
55. Install the coolant bypass tube.
56. Install the ground strap on the rear of the RH cylinder head. Install the stud bolt and tighten to 25 Nm (18 lb-ft). Install the ground strap. Install the retaining nut and tighten to 10 Nm (89 lb-in).
57. Install the new intake manifold gaskets, intake manifold and hand-tighten the bolts at the locations shown in illustration.
58. Install the 8 ignition coils and tighten the 8 bolts (4 shown in illustration). Tighten to 6 Nm (53 lb-in).
59. Install the intake manifold bracket and loosely install the bolt and the stud bolt.
60. Install the thermostat.
61. Install the coolant outlet adapter and loosely install the 2 bolts.
62. Tighten the bolts in the sequence shown in illustration. Tighten to 25 Nm (18 lb-ft).
63. Tighten the stud bolt. Tighten to 25 Nm (18 lb-ft).
64. Tighten the bolts. Tighten to 25 Nm (18 lb-ft).
65. Connect the EGR tube to the EGR valve. Tighten to 43 Nm (32 lb-ft).
66. Connect the EGR tube-to-exhaust manifold connector. Tighten to 43 Nm (32 lb-ft).
67. Position the fuel charging wiring at 2 locations at the back of the intake manifold.
68. Install the generator and the 2 bolts. Tighten to 25 Nm (18 lb-ft).
69. Connect the throttle control and the Throttle Position (TP) sensor electrical connector.
70. Install the generator mounting bracket and the 4 bolts. Tighten to 10 Nm (89 lb-in).
71. Attach the wire harness retainer and connect the generator electrical connector.
72. Connect the electrical connector to the EGR vacuum regulator solenoid.
73. Connect the crankcase ventilation tube.
74. Install the intake manifold shield and the 2 bolts. Tighten to 10 Nm (89 lb-in).
75. Connect the 8 fuel injector electrical connectors (4 shown in illustration).
76. Connect the 8 ignition coil electrical connectors.
77. Connect the Camshaft Position (CMP) sensor electrical connector.
78. Connect the radio interference capacitor electrical connector.
79. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
80. Install the battery cables and the bolt.
81. Install the Engine Lifting Bracket to the RH cylinder head.
82. Install the Engine Lifting Bracket to the LH cylinder head.
83. Using the Engine Lifting Bracket Set, remove the engine from the engine stand.
84. Install the engine/transmission spacer plate.
85. Position the flexplate and install the bolts in the sequence shown in illustration. Tighten to 80 Nm (59 lb-ft).
86. Install the engine. For additional information, refer to «Engine»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v) .
87. If equipped with fire suppression system, repower the system

Special Tools Illustration Tool Name Tool Number Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) or equivalent Socket, Exhaust Gas Oxygen Sensor 303-476 (T94P-9472-A)

Material

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/mercury/grand-marquis/iv-2005-2011/remont/hoistjack/#jacking-and-lifting) article.
2. Using the Engine Lifting Bracket Set, install the engine assembly in the vehicle.
3. Install the 4 transmission bellhousing bolts and 1 stud. Tighten to 48 Nm (35 lb-ft).
4. Attach the wiring harness to the retainers on the transmission.
5. Connect the Output Shaft Speed (OSS) sensor, Transmission Range (TR) sensor and the Turbine Shaft Speed (TSS) sensor electrical connectors.
6. Connect the Heated Oxygen Sensor (HO2S) and the solenoid body sensor electrical sensors.
7. Raise the transmission and install the transmission insulator.
8. Install the 2 insulator bolts. Tighten to 90 Nm (66 lb-ft).
9. Lower the transmission and install the 2 transmission insulator nuts. Tighten to 30 Nm (22 lb-ft).
10. Install the 2 engine mount nuts. Tighten to 90 Nm (66 lb-ft).
11. Using the Exhaust Gas Oxygen Sensor Socket, install the HO2S. Calculate the correct torque wrench setting for the following torque. For additional information, Tighten to 40 Nm (30 lb-ft).
12. Connect the LH HO2S electrical connector.
13. Connect the RH HO2S electrical connector.
14. Install the 4 torque converter nuts. Rotate the crankshaft to access the nuts. Tighten to 36 Nm (27 lb-ft).
15. Install the rubber access plug.
16. Install the inspection cover and the 3 bolts. Tighten to 19 Nm (168 lb-in).
17. Install the starter motor. For additional information, refer to «STARTING SYSTEM»(/mercury/grand-marquis/iv-2005-2011/remont/starter/#starting-system) article.
18. Position the exhaust, install the 4 new nuts and remove the support. Tighten to 48 Nm (35 lb-ft).
19. Install the power steering pump and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
20. Install the A/C compressor and the 3 bolts. Tighten to 25 Nm (18 lb-ft).
21. Connect the A/C compressor electrical connector.
22. Connect the engine wiring harness retainers to the A/C compressor.
23. Connect the Crankshaft Position (CKP) sensor electrical connector.
24. Position the transmission oil cooler tube bracket and install the bolt. Tighten to 15 Nm (133 lb-in).
25. Install the transmission cooler tube support bracket. Tighten to 9 Nm (80 lb-in).
26. Install the power steering tube bracket. Tighten to 10 Nm (89 lb-in).
27. If equipped, install a new oil cooler and oil cooler hoses. For additional information, refer to «Oil Cooler»(/mercury/grand-marquis/iv-2005-2011/remont/mechanical/#engine-46l-2v__oil-cooler) .
28. Connect the Power Steering Pressure (PSP) switch electrical connector.
29. Connect the power steering electrical connector.
30. If equipped, connect the block heater electrical connector.
31. Connect the EOP switch electrical connector.
32. Install the 2 top transmission bellhousing bolts. Tighten to 48 Nm (35 lb-ft).
33. Install the oil filter.
34. Install the cooling fan. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
35. Connect the lower radiator hose.
36. Connect the upper radiator hose to the hose connection.
37. Connect the PCM electrical connectors.
38. Position the ground strap and install the bolt. Tighten to 10 Nm (89 lb-in).
39. Connect the heater hoses.
40. Connect the A/C low charge protection switch electrical connector.
41. Connect the A/C electrical connector.
42. Install the ground strap and the bolt. Tighten to 10 Nm (89 lb-in).
43. Attach the pin-type retainer and install the generator battery cable and nut. Tighten to 9 Nm (80 lb-in).
44. Attach the generator battery cable retainer to the RH valve cover stud bolt.
45. Connect the fuel tube spring lock coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/fuel-system/#fuel-system-general-information) article.
46. Connect the 2 hoses and the Evaporative Emission (EVAP) canister purge valve electrical connection.
47. Connect the vacuum hose.
48. Install the air cleaner and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/mercury/grand-marquis/iv-2005-2011/remont/removal-installation/#intake-air-distribution-and-filtering) article.
49. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(/mercury/grand-marquis/iv-2005-2011/remont/accessory-drive-belts/#accessory-drive-system) article.
50. Install the support bracket and the 2 nuts. Tighten to 10 Nm (89 lb-in).
51. Install the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS & WASHERS»(/mercury/grand-marquis/iv-2005-2011/remont/wiperwasher-systems/#wiper-system-washer-system) article.
52. Fill the crankcase with clean engine oil.
53. Connect both battery cables. For additional information, refer to «CHARGING SYSTEM - GENERAL INFORMATION»(/mercury/grand-marquis/iv-2005-2011/remont/charging-system/#charging-system-general-information) article.
54. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(/mercury/grand-marquis/iv-2005-2011/remont/cooling-system-mechanical/#engine-cooling-system) article.
55. Install the hood.
56. If equipped with fire suppression system, repower the system.

See also:
• Introduction - Gasoline Engines
• ENGINE SYSTEM - GENERAL INFORMATION
• FIRE SUPPRESSION SYSTEM
• JACKING & LIFTING
• FUEL SYSTEM - GENERAL INFORMATION
• BATTERY, MOUNTING & CABLES
• ENGINE COOLING
• INTAKE AIR DISTRIBUTION & FILTERING
• WIPERS & WASHERS
• ENGINE EMISSION CONTROL
• EVAPORATIVE EMISSIONS
• SUPPLEMENTAL RESTRAINT SYSTEM
• ELECTRONIC ENGINE CONTROLS
• FULL FRAME & BODY MOUNTING
• AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70E/4R75E
• CHARGING SYSTEM - GENERAL INFORMATION
• ACCESSORY DRIVE
• STARTING SYSTEM
• Engine Mount - LH
• Crankshaft Pulley
• Valve Cover - RH
• Valve Cover - LH
• Crankshaft Front Seal
• Engine Front Cover
• Camshaft Roller Follower
• Valve Springs
• Timing Drive Components
• Engine Lubrication Components - Exploded View, Oil Pan, Oil Pump, Oil Pump Screen and Pickup Tube
• Oil Pan
• Oil Cooler
• Cylinder Head